A kind of active and passive integrated fireproof insulation board and its preparation method

Abstract

The present application relates to a kind of active and passive integrated fireproof insulation board and its preparation method, including n passive fireproof layer and n or n+1 active fireproof layer;Passive fireproof layer and active fireproof layer are integrated;Passive fireproof layer includes inorganic fiber felt and aerogel;Aerogel is obtained by curing adhesive aerogel stock solution, stock solution includes: 1000-4000 parts of silica sol by mass, silicate 50-150 parts, phosphate binder 10-50 parts, quicklime 5-20 parts, titanium white 5-50 parts, calcium stearate 10-50 parts, hydrophobic modifier 5-50 parts, acid-base regulator 5-50 parts and solvent 1000-4000 parts;Active fireproof layer is at least one of inorganic fireproof board material with heat decomposition active energy consumption, such as gypsum fireproof board.The present application solves the problems such as high organic content, poor flame retardance, high hygroscopicity and significant decline in thermal insulation performance and safety after use in existing fireproof insulation board.

Description

Technical Field

[0001] This invention relates to the field of building materials technology, and in particular to an integrated active and passive fireproof and heat-insulating board and its preparation method. Background Technology

[0002] Fire-resistant and thermally insulated integrated panels are building materials that combine fire resistance and thermal insulation functions. They are commonly used for exterior walls, interior walls, and roofs to improve building safety and energy efficiency. In the event of a fire, they can slow the spread of fire, buy time for evacuation, reduce property damage, and effectively reduce heat exchange between the building's interior and exterior, thereby lowering energy consumption for air conditioning and heating systems and achieving energy conservation and emission reduction. Fire-resistant and thermally insulated integrated panels typically consist of a multi-layered structure, including a fire-resistant layer made of non-combustible or flame-retardant materials, a thermal insulation layer made of heat-insulating phase change materials, and other functional layers. Current fire-resistant and thermally insulated integrated panels have the following problems:

[0003] (1) Due to the use of organic adhesives to bond different functional layers, the fire resistance of fireproof and heat-insulating integrated panels is difficult to reach Class A non-combustible. Furthermore, the organic components in fireproof and heat-insulating integrated panels will release a large amount of toxic and harmful gases in high-temperature environments or during combustion, making the fire environment more severe, increasing the difficulty of personnel evacuation, and causing environmental pollution.

[0004] (2) Because organic materials such as polystyrene board and polystyrene are used as phase change materials in fireproof and heat-insulating integrated panels, the fireproof performance of the fireproof and heat-insulating integrated panels is insufficient, resulting in huge fire safety hazards.

[0005] (3) Because porous inorganic fiber materials such as rock wool and perlite are used as insulation materials in fireproof and heat-insulating integrated panels, these panels have high water absorption and poor weather resistance. Water absorption and moisture absorption will severely reduce the structural safety and service life of the fireproof and heat-insulating integrated panels, making them unable to withstand the effects of severe weather and environmental factors. Furthermore, water absorption and moisture absorption will also reduce the fireproof and heat-insulating effect of the fireproof and heat-insulating integrated panels.

[0006] Chinese patent application CN115503300A discloses a composite rock wool fireproof, thermal insulation, and decorative integrated panel, comprising, from top to bottom, a rock wool insulation layer, a surface treatment layer, and a decorative layer. The surface treatment layer is composed of a surface treatment agent, including BC-413 pure acrylic emulsion, VAE705 emulsion, and water. The rock wool insulation layer is composed of rock wool felt and silica aerogel slurry. The decorative layer is composed of silicate cement, fine sand, stone powder, water-reducing agent, sodium polynaphthalene sulfonate, curing agent, and water. This solution increases the bonding strength of the rock wool composite insulation board through the surface treatment layer, improves the tensile strength of the rock wool insulation layer and the decorative layer, and enhances the board's acid and alkali resistance. By combining rock wool felt with silica aerogel to obtain the rock wool insulation layer, the thermal insulation and fireproof performance is improved. The silica aerogel undergoes hydrophobic treatment to reduce its hygroscopicity. This solution overcomes the first two shortcomings of the fireproof and heat-insulating integrated panel, but it does not treat the rock wool in any way and still uses a lot of organic components. This greatly reduces the fireproof performance and environmental friendliness of the fireproof and heat-insulating panel. Furthermore, the problems of high water absorption and poor weather resistance of rock wool have not been effectively solved, affecting long-term use and safety.

[0007] Therefore, it is necessary to improve existing technologies to obtain a fireproof and heat-insulating integrated panel with high fire safety performance, good thermal insulation effect and low moisture absorption. Summary of the Invention

[0008] (a) Technical problems to be solved

[0009] In view of the above-mentioned shortcomings and deficiencies of the prior art, the present invention provides an integrated active and passive fireproof and heat-insulating board, which solves the problems of high organic content, insufficient fire resistance and environmental protection, high moisture absorption, and decline in performance and safety after long-term use in the existing fireproof and heat-insulating integrated board.

[0010] (II) Technical Solution

[0011] To achieve the above objectives, the main technical solutions adopted by the present invention include:

[0012] In a first aspect, the present invention provides an integrated active and passive fireproof insulation board, comprising: n passive fireproof layers and n or n+1 active fireproof layers, wherein n is a natural number; the passive fireproof layers and the active fireproof layers are stacked together as a single unit;

[0013] The passive fireproof layer comprises an inorganic fiber felt as a porous skeleton material and an aerogel that fills and coats the pores of the skeleton material. The aerogel is obtained by curing and drying an adhesive aerogel stock solution, which comprises, by mass, 1000-4000 parts of silica sol, 50-150 parts of soluble silicate, 10-50 parts of phosphate binder, 5-20 parts of quicklime, 5-50 parts of titanium dioxide, 10-50 parts of calcium stearate, 5-50 parts of hydrophobic modifier, 10-50 parts of acid-base adjuster, and 1000-4000 parts of solvent.

[0014] According to a preferred embodiment of the present invention, the active fireproof layer may be at least one of inorganic fireproof boards that have active energy dissipation upon thermal decomposition, such as gypsum fireproof board, magnesium oxide fireproof board, cement fiberboard, and silicate fiberboard.

[0015] According to a preferred embodiment of the present invention, the inorganic fiber felt may be a fiber felt composed of one or more of mullite fiber felt, aluminosilicate fiber felt, glass fiber felt, and alumina fiber felt.

[0016] According to a preferred embodiment of the present invention, in the passive fireproof layer, the inorganic fiber felt accounts for 70-95% by mass, preferably 85-90%; the remainder is aerogel.

[0017] According to a preferred embodiment of the present invention, the phosphate adhesive may be at least one selected from aluminum dihydrogen phosphate, magnesium phosphate, and zinc phosphate. These phosphate adhesives have both adhesive and flame-retardant properties. Aluminum dihydrogen phosphate is preferred, as it possesses strong high-temperature resistance and flame retardancy.

[0018] According to a preferred embodiment of the present invention, the soluble silicate may be at least one of lithium silicate, sodium silicate, and potassium silicate. These silicates act as pH adjusters, inorganic binders, and catalysts, accelerating the polycondensation reaction of sol precursors (such as silica sol) to form a more uniform and stable sol system, thereby obtaining a higher quality aerogel; they can also modify the structure of the silicon-oxygen framework to a certain extent. They primarily enhance the network structure by introducing additional silicon-oxygen bonds, thereby improving the mechanical strength and thermal stability of the aerogel. Furthermore, soluble silicates can control the density and porosity of the aerogel; by changing the proportions, aerogels with different pore size distributions and specific surface areas can be prepared.

[0019] According to a preferred embodiment of the present invention, the silica sol is a commercially available silica sol product with a solid content >25%.

[0020] According to a preferred embodiment of the present invention, the hydrophobic modifier may be at least one of polydimethylsiloxane, trimethylchlorosilane, hexamethyldisilazane, hexamethyldisilazane, methyltrimethoxysilane, methyltriethoxysilane, dimethyldimethoxysilane, and dimethyldiethoxysilane; the acid-base regulator may be at least one of acetic acid, hydrochloric acid, phosphoric acid, ammonia, ammonium carbonate, and ammonium bicarbonate; and the solvent may be water, methanol, or ethanol, preferably water.

[0021] According to a preferred embodiment of the present invention, in the adhesive aerogel stock solution, the silica sol is preferably 1000-2000 parts, 2000-3000 parts, 3000-3500 parts, or 3500-4000 parts; the soluble silicate is preferably 50-70 parts, 70-90 parts, 90-110 parts, 110-130 parts, or 130-150 parts; the phosphate adhesive is preferably 10-20 parts, 20-30 parts, 30-40 parts, or 40-50 parts; and the quicklime is preferably 5-8 parts, 8-12 parts, or 1... 2-15 parts, 15-17 parts, or 17-20 parts; titanium dioxide is preferably 5-15 parts, 15-30 parts, 30-40 parts, or 40-50 parts; calcium stearate is preferably 10-20 parts, 20-30 parts, 30-40 parts, or 40-50 parts; hydrophobic modifier is preferably 5-15 parts, 15-30 parts, 30-40 parts, or 40-50 parts; acid-base regulator is preferably 10-20 parts, 20-30 parts, 30-40 parts, or 40-50 parts; the solvent is water, preferably 2000-4000 parts.

[0022] According to a preferred embodiment of the present invention, the adhesive aerogel stock solution further contains 10-30 parts by weight of phase change microcapsule material. The shell of the phase change microcapsule material is silica, melamine-formaldehyde resin, polyurea-polyurethane, or polyamide, and the phase change core material of the phase change microcapsule material is at least one of paraffin wax, alkanes, fatty acids and their esters, sodium sulfate dodecahydrate, calcium chloride hexahydrate, polyethylene glycol, and neopentyl glycol. The polyurea-polyurethane or polyamide can be further improved in terms of flame retardant properties by introducing monomers or additives containing flame retardant elements such as phosphorus, halogens, and nitrogen.

[0023] Preferably, the shell of the phase change microcapsule material is silica, which has good compatibility with silica aerogel and is an inorganic material with good flame retardancy. Secondly, melamine-formaldehyde resin is chosen; although it is an organic polymer, this resin can expand and form a char layer when heated, providing additional protection and thus also possessing some flame retardancy. When silica is used as the shell material of the phase change microcapsules, the phase change core material can be encapsulated using a sol-gel method.

[0024] Secondly, the present invention also provides a method for preparing an integrated active and passive fireproof insulation board, comprising the following steps:

[0025] S1: Prepare the raw materials according to the composition of the adhesive aerogel stock solution in the above scheme. Divide the solvent into two parts. Add soluble silicate, quicklime and titanium dioxide to one part of the solvent and stir to obtain mixed solution 1. Add silica sol and phosphate adhesive to the other part of the solvent and stir to obtain mixed solution 2.

[0026] S2: Mix solution 1 and solution 2 and stir. During stirring, add an acid-base adjuster to adjust the pH to 6-7 to obtain solution 3.

[0027] S3: Add calcium stearate and hydrophobic modifier to mixed solution 3 and stir to obtain adhesive aerogel stock solution;

[0028] S4: Impregnate the inorganic fiber felt with the adhesive aerogel stock solution until it is fully saturated to obtain the inorganic fiber felt impregnated with the aerogel stock solution.

[0029] S5: The inorganic fiber felt impregnated with aerogel solution is laminated with the active fireproof layer to obtain an unshaped fireproof insulation board.

[0030] S6: The unshaped fireproof insulation board is first subjected to pressure gel shaping and curing, and then microwave drying and aging treatment to obtain an integrated active and passive fireproof insulation board.

[0031] According to a preferred embodiment of the present invention, in step S2, during the mixing and stirring of mixed solution 1 and mixed solution 2, an acid-base adjuster is added to adjust the pH to 6. Under weakly acidic conditions, the silica sol exhibits better stability, a slower reaction rate, and better adjustability of the pore structure.

[0032] Preferably, in S1, the stirring speed is low-speed stirring at 100-800 rpm, and approximately 1 / 2 of the total solvent volume is used each time; in S2, the stirring speed is high-speed stirring at 1500-2000 rpm; and in S3, the stirring speed is low-speed stirring at 100-800 rpm.

[0033] According to a preferred embodiment of the present invention, in step S3, phase change microcapsule material may also be added together with calcium stearate.

[0034] According to a preferred embodiment of the present invention, in step S4, before impregnating the inorganic fiber felt, the inorganic fiber felt is dried to remove moisture from the inorganic fiber felt, so that the inorganic fiber felt can fully absorb the adhesive aerogel stock solution prepared in the above steps.

[0035] According to a preferred embodiment of the present invention, in step S6, the conditions for pressure gel shaping and curing are: maintaining a pressure of 2-5 MPa and a temperature of 30-50°C for curing; the conditions for microwave drying and aging treatment are: drying and aging for 1-30 minutes in a microwave band with a frequency of 1000-2500 MHz and a temperature of 50-100°C.

[0036] (III) Beneficial Effects

[0037] 1. The present invention provides an integrated active and passive fireproof insulation board. Since no organic adhesive is used between the active fireproof layer and the passive fireproof layer, compared with the prior art, the integrated fireproof insulation board of the present invention has a lower organic content, higher fire resistance, and a fire resistance limit time of more than 1.5 hours, and can reach a non-combustible rating of A2 or above.

[0038] 2. Because the passive fireproof layer of the present invention adopts a composite structure of aerogel and inorganic fiber felt, and phosphate binder (preferably aluminum dihydrogen phosphate) and titanium dioxide are added to the aerogel, the phosphate binder is an inorganic adhesive, which not only has good fireproof performance, but also good adhesion. Quicklime promotes the hydrolysis of silica sol in the passive fireproof layer and enhances the strength of the aerogel, while enhancing the bonding strength between the aerogel and the fiber, and between the passive fireproof layer and the active fireproof layer.

[0039] By adding phosphate binder, the aerogel solution has good adhesion, which allows the aerogel to be firmly bonded to the inorganic fiber felt to improve the strength of the insulation board. It also allows the inorganic fiber felt impregnated with aerogel solution to be well integrated with the active fireproof layer under pressure treatment (2-5MPa) to form an integrated structure, avoiding delamination and improving durability.

[0040] 3. This invention further enhances the hydrophobicity of the fireproof and thermal insulation integrated board by adding a hydrophobic modifier to the passive fireproof layer. Compared to existing technologies, the 24-hour water absorption rate of the fireproof and thermal insulation board of this invention is reduced from 70% to 4%. Since the hydrophobic modifier is added to the aerogel stock solution, it also modifies the inorganic fiber felt during impregnation and coating. Compared to existing technologies, this significantly reduces the hygroscopicity of the inorganic fiber felt, improves the weather resistance of the insulation board, prevents the insulation board from becoming too heavy after absorbing moisture and peeling off from the building, and enhances safety in use.

[0041] 4. This invention significantly improves the fire resistance limit of the integrated fireproof and thermal insulation board by synergistically leveraging the active fireproof layer's chemical reaction to absorb heat and release water vapor during a fire, and the passive fireproof layer's low thermal conductivity to insulate heat. The sandwich structure (with an inorganic fiber felt-reinforced aerogel layer in between) of the integrated active and passive fireproof and thermal insulation board increases the fire resistance limit by more than 30% compared to a single-layer active fireproof board of the same thickness. During fire protection, the temperature of the unexposed side decreases by 0-30℃ during the plateau phase of the temperature rise curve, and the equivalent thermal conductivity can reach below 0.09W / (mK).

[0042] 5. Because this invention introduces a large amount of aerogel and inorganic fibers into the fireproof insulation board, it significantly reduces the equivalent density of the fireproof insulation board while meeting structural strength requirements. This results in a lightweight and high-strength board suitable for steel structure buildings and prefabricated buildings. The insulation board can be treated with a decorative layer on the surface of the active fireproof layer as needed to improve both fireproof and thermal insulation performance and aesthetics.

[0043] 6. Furthermore, in some embodiments of the present invention, a small amount of phase change microcapsule material is added to the aerogel stock solution to enhance the active temperature regulation function of the insulation board, achieve heat insulation / cold insulation, reduce indoor heat / cold loss, reduce building energy loss, and achieve energy saving. Attached Figure Description

[0044] Figure 1 The active and passive integrated fireproof and heat-insulating board is shown in Example 1.

[0045] Figure 2 Example 4 shows an integrated active and passive fireproof and heat-insulating board.

[0046] Figure 3 The temperature curves of the fire-exposed and unexposed sides of the fireproof insulation board are shown.

[0047] Figure 4 This is the temperature curve of the unexposed side of the fireproof insulation board.

[0048] Figure 5 The image shows the state of the active and passive integrated fireproof and heat-insulating board in Example 1 during a combustion test.

[0049] Figure 6 The back of the active and passive integrated fireproof and heat-insulating board after the combustion test of Example 1. Detailed Implementation

[0050] To better explain and facilitate understanding of the present invention, the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0051] The present invention proposes an integrated active and passive fireproof insulation board, comprising n passive fireproof layers and n or n+1 active fireproof layers, wherein n is a natural number; the passive fireproof layers and the active fireproof layers are stacked together as a whole.

[0052] The passive fireproof layer comprises an inorganic fiber felt as a porous skeleton material and an aerogel that fills and coats the pores of the skeleton material. The aerogel is obtained by curing and drying an adhesive aerogel stock solution, which comprises, by mass, 1000-4000 parts of silica sol, 50-150 parts of soluble silicate, 10-50 parts of phosphate binder, 5-20 parts of quicklime, 5-50 parts of titanium dioxide, 10-50 parts of calcium stearate, 5-50 parts of hydrophobic modifier, 5-50 parts of acid-base adjuster, and 1000-4000 parts of solvent.

[0053] Aerogel, as a porous and highly efficient thermal insulation material, possesses characteristics such as low density, low thermal conductivity, and high specific surface area due to its extremely high porosity. The adhesive aerogel stock solution prepared in this invention can further improve the fire resistance, temperature regulation, corrosion resistance, hydrophobicity, adhesion, and structural strength of aerogel.

[0054] The present invention combines a passive fireproof layer and an active fireproof layer. By synergistically leveraging the active fireproof layer's active fireproofing function of decomposing and absorbing heat and releasing water vapor during fire, and the passive fireproofing function of the passive fireproof layer's low thermal conductivity and heat insulation, the fire resistance limit of the integrated fireproof and heat-insulating panel is significantly improved. A three-layer composite fireproof and heat-insulating panel, with an inorganic fiber felt-reinforced aerogel layer in the middle and an active fireproof layer on top and bottom, achieves a fire resistance limit that is more than 30% higher than that of an active fireproof panel of the same thickness. During fire protection, the temperature during the plateau phase of the temperature rise curve on the unexposed side is reduced by 0-30°C.

[0055] Preferably, the active fireproof layer can be at least one of gypsum fireproof board, magnesium oxide fireproof board, cement fiberboard, silicate fiberboard, and inorganic composite board. Commonly available fireproof boards that absorb heat and release water vapor during decomposition can be used, and the thickness of the active fireproof layer is 10-150mm.

[0056] Preferably, the inorganic fiber felt can be a fiber felt composed of one or more of mullite fiber felt, aluminosilicate fiber felt, glass fiber felt, and alumina fiber felt. Commercially available inorganic fiber felts can be used. Preferably, the thickness of the inorganic fiber felt is 5-30 mm.

[0057] Preferably, in the passive fireproof layer, the inorganic fiber felt accounts for 70-95% of the mass, more preferably 85-90%; the remainder is aerogel; thereby greatly improving the structural strength of the passive fireproof layer and facilitating its assembly with metal parts such as screws in building walls.

[0058] Preferably, the silica sol is a commercially available product with a solid content exceeding 25%. Commercially available silica sol products are dispersions containing nano-sized silica particles uniformly distributed in water or organic solvents.

[0059] Preferably, the phosphate adhesive can be at least one of aluminum dihydrogen phosphate, magnesium phosphate, and zinc phosphate. These phosphate adhesives function as both adhesives and flame retardants. Aluminum dihydrogen phosphate is particularly preferred, as it exhibits strong high-temperature resistance and flame retardancy, and can also act as a catalyst to promote the hydrolysis of silica sol in the aerogel raw material and enhance the strength of the aerogel. The phosphate adhesive can promote the adhesion of the aerogel concentrate, allowing it to adhere well to the inorganic fiber felt, and also enabling the inorganic fiber felt impregnated with the aerogel concentrate to firmly bond with the active fireproof layer to form an integrated insulation board.

[0060] Preferably, the soluble silicate can be at least one of lithium silicate, sodium silicate, and potassium silicate. These soluble silicates can alter the structure of the silicon-oxygen framework. They primarily enhance the network structure by introducing additional silicon-oxygen bonds, thereby improving the mechanical strength and thermal stability of the aerogel. Furthermore, soluble silicates can control the density and porosity of the aerogel; by changing the proportions, aerogels with different pore size distributions and specific surface areas can be prepared.

[0061] Preferably, quicklime and metal oxides such as titanium dioxide are added to the aerogel stock solution to form an inorganic binder together with aluminum dihydrogen phosphate. This can promote the hydrolysis of silica sol during the preparation of the passive fireproof layer and enhance the strength of the aerogel, improve the durability of the connection between the passive fireproof layer and the active fireproof layer, and prevent peeling at the connection between the passive fireproof layer and the active fireproof layer after long-term use.

[0062] Preferably, the calcium stearate added to the aerogel stock solution can be used to modify the surface of the aerogel particles, imparting hydrophobicity; it helps prevent the aggregation of nano-sized particles, thereby improving the stability of the aerogel stock solution to obtain a uniform aerogel structure, avoiding the formation of large pores or uneven density distribution, and enhancing the mechanical strength, toughness, and high-temperature stability of the aerogel. Calcium stearate can also be used as a lubricant to improve mixing uniformity and flowability, making the processing smoother.

[0063] Preferably, a hydrophobic modifier is added to the aerogel stock solution to change the water absorption of the aerogel, preventing the pores in the aerogel from absorbing water, which would increase the weight of the insulation board and create safety hazards.

[0064] Preferably, the acid-base regulator can be at least one of acetic acid, hydrochloric acid, phosphoric acid, sulfuric acid, ammonia, ammonium carbonate, and ammonium bicarbonate. The acid-base regulator provides a weakly acidic environment to appropriately stabilize the aerogel stock solution and prevent problems such as low aerogel strength and uneven pore size / structure distribution caused by excessively rapid aerogel formation.

[0065] Preferably, the adhesive aerogel stock solution further contains 10-30 parts by weight of phase change microcapsule material. The shell of the phase change microcapsule material is silica, melamine-formaldehyde resin, polyurea-polyurethane, or polyamide, and the phase change core material is at least one of paraffin wax, alkanes, fatty acids and their esters, sodium sulfate dodecahydrate, calcium chloride hexahydrate, polyethylene glycol, and neopentyl glycol. The silica shell and melamine-formaldehyde resin themselves are flame retardant. The polyurea-polyurethane or polyamide can be further improved by introducing monomers or additives containing flame retardant elements such as phosphorus, halogens, and nitrogen.

[0066] More preferably, the shell of the phase change microcapsule material is silica, which has good compatibility with silica aerogel. When silica is used as the shell material of the phase change microcapsule, the phase change core material can be encapsulated by the sol-gel method, and preparation can be carried out with reference to existing technology.

[0067] This invention also provides a method for preparing an integrated active and passive fireproof insulation board, comprising:

[0068] S1: Prepare the raw materials according to the composition of the adhesive aerogel stock solution in the above scheme. Divide the solvent into two parts. Add soluble silicate, quicklime and titanium dioxide to one part of the solvent and stir to obtain mixed solution 1. Add silica sol and phosphate adhesive to the other part of the solvent and stir to obtain mixed solution 2.

[0069] S2: Mix solution 1 and solution 2 and stir. During stirring, add an acid-base adjuster to adjust the pH to 6-7 to obtain solution 3.

[0070] S3: Add calcium stearate and hydrophobic modifier to mixed solution 3 and stir to obtain adhesive aerogel stock solution;

[0071] S4: Impregnate the inorganic fiber felt with the adhesive aerogel stock solution until it is fully saturated to obtain the inorganic fiber felt impregnated with the aerogel stock solution.

[0072] S5: The inorganic fiber felt impregnated with aerogel solution is laminated with the active fireproof layer to obtain an unshaped fireproof insulation board.

[0073] S6: The unshaped fireproof insulation board is first subjected to pressure gel shaping and curing, and then microwave drying and aging treatment to obtain an integrated active and passive fireproof insulation board.

[0074] Preferably, the stirring speed in step S1 is 100-800 r / min.

[0075] Preferably, the stirring speed in step S2 is 1500-2000 r / min.

[0076] Preferably, in step S2, an acid-base regulator is added to adjust the pH during the mixing and stirring of mixed solution 1 and mixed solution 2, so that the pH of the aerogel stock solution obtained after stirring is 6. A weakly acidic environment is maintained during the stirring process. At this time, the silica sol has better stability, a slower reaction rate, and better adjustability of pore structure. However, the acidic environment should not be too strong, so as not to cause the aerogel formation rate to be too slow, which would affect the lengthening of the insulation board molding cycle and reduce the strength of the aerogel.

[0077] Preferably, in step S3, the stirring speed is 100-800 r / min. In embodiments where phase change microcapsule material is added, the phase change microcapsule material can be added in this step and stirred at a low speed to ensure uniformity, thus avoiding damage to the phase change microcapsule material from the shear force of high-speed stirring.

[0078] Preferably, in step S4, before impregnating the inorganic fiber felt, the inorganic fiber felt is dried at a temperature of 40-120°C for 12-24 hours. During impregnation, the impregnation time is 2-30 minutes. The thickness of the inorganic fiber felt is 5-30 mm.

[0079] Preferably, in step S5, when the inorganic fiber felt impregnated with aerogel stock solution is laminated with the active fireproof layer, an alternating lamination method or a sandwich lamination method can be used. Specifically, in the alternating lamination method, one layer of inorganic fiber felt can be alternately laminated with one layer of active fireproof layer, or two or more layers of inorganic fiber felt can be grouped together with two or more layers of active fireproof layer, and then alternately laminated group by group.

[0080] Preferably, in step S6, a plastic film (protective film) is wrapped around the unshaped fireproof insulation board, followed by pressure gel curing, maintaining a pressure of 2-5 MPa and a temperature of 30-50°C for 15 minutes to 1 hour; the plastic film prevents rapid evaporation of moisture; after pressure gel curing, microwave drying and aging treatment is performed, with a microwave frequency of 1000-2500 MHz, a temperature of 50-100°C, and an aging time of 1-30 minutes. Microwave drying and aging not only strengthens the bond between the passive fireproof layer and the active fireproof layer, but also further decomposes or evaporates the organic materials introduced during the preparation of the fireproof insulation board, reducing the organic content in the fireproof insulation board and improving its flame retardancy.

[0081] To better understand the above technical solutions, exemplary embodiments of the present invention will be described in more detail below with reference to the accompanying drawings. Although exemplary embodiments of the present invention are shown in the drawings, it should be understood that the present invention can be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that the present invention can be understood more clearly and thoroughly, and that the scope of the present invention can be fully conveyed to those skilled in the art.

[0082] Example 1

[0083] like Figure 1 As shown in this embodiment, an integrated active and passive fireproof insulation board includes a passive fireproof layer and two layers of commercially available magnesium oxide fireproof boards. The two layers of commercially available magnesium oxide fireproof boards are located on two sides of the passive fireproof layer, forming a sandwich structure. The passive fireproof layer includes aerogel and 30-dimensional aluminum silicate fiber felt. The aerogel is formed by the curing of aerogel stock solution filling the gaps in the aluminum silicate fiber felt and wrapping the outside of the aluminum silicate fiber felt. The thickness of the aluminum silicate fiber felt is 15 mm. The aerogel stock solution contains, by weight, 1000 parts silica sol, 15 parts aluminum dihydrogen phosphate, 100 parts lithium silicate, 10 parts quicklime, 10 parts titanium dioxide, 10 parts calcium stearate, 50 parts polydimethylsiloxane (hydrophobic modifier), 5 parts acetic acid (pH adjuster), and 3000 parts water.

[0084] The method for preparing the fireproof and heat-insulating board is as follows:

[0085] S1: Prepare the raw materials and solvents according to the proportions; add lithium silicate, quicklime and titanium dioxide to 1 / 2 of the water and stir at a stirring speed of 500 r / min to obtain mixed solution 1; add silica sol and aluminum dihydrogen phosphate to the remaining 1 / 2 of the water and stir at a stirring speed of 500 r / min to obtain mixed solution 2.

[0086] S2: Mix solution 1 and mixed solution 2 and stir at a speed of 1500 r / min. During the stirring process, add acetic acid to adjust the pH to 6. After stirring, mixed solution 3 is obtained.

[0087] S3: Add calcium stearate and polydimethylsiloxane to mixed solution 3 and stir at a speed of 500 r / min. After stirring at low speed, an adhesive aerogel stock solution is obtained.

[0088] S4: Dry the aluminum silicate fiber felt at a temperature of 100°C for 18 hours. Then, immerse the dried aluminum silicate fiber felt in the above-mentioned adhesive aerogel solution for 20 minutes to obtain aluminum silicate fiber felt impregnated with the aerogel solution.

[0089] S5: Lay the aluminum silicate fiber felt impregnated with aerogel solution onto the magnesium oxide fireproof board, and then lay another magnesium oxide fireproof board on the other side of the aluminum silicate fiber felt to obtain an unshaped fireproof and heat-insulating board.

[0090] S6: Wrap a layer of PVA plastic film around the unshaped fireproof insulation board, then apply 2MPa to the unshaped fireproof insulation board and cure the gel in a curing chamber at 45℃ for 30 minutes. After the gel sets, transfer it to a microwave band with a frequency of 1000-2500MHz and age it at 60℃ for 30 minutes. At this point, the preparation of the integrated active and passive fireproof insulation board is complete.

[0091] The active and passive integrated fireproof insulation board of this embodiment was subjected to a 1200℃ combustion test (see test conditions). Figure 5 (Photos), recording the fire-exposed temperature and unexposed temperature of the fireproof insulation board. The temperature curve for fire-exposed temperature 1 is shown in the figure. Figure 3 As shown, the temperature curve for backfire temperature 1 is as follows: Figure 3 , Figure 4 As shown ( Figure 3 The three backfire temperature curves basically overlap. Figure 4 (This is an enlarged view of the three backfire temperature curves). As shown in the figure, when the initial flame temperature (1) is 1000-1300℃, the backfire temperature (1) never exceeds 200℃ during the 0-90 minute combustion test, especially maintaining a low temperature of 70-90℃ during the 0-75 minute combustion test. After the combustion test, the backfire surface of this embodiment was observed, as shown... Figure 6 As shown, the unexposed side retains the original color of the insulation board and does not exhibit any blackening. The equivalent density of the integrated fireproof insulation board in this embodiment is only 0.7 g / cm³. 3 Therefore, it can be seen that the active and passive integrated fireproof and heat-insulating board of this embodiment has a very low equivalent density, is lightweight, and has excellent flame-retardant and heat-insulating effects.

[0092] Example 2

[0093] This embodiment provides an integrated active and passive fireproof insulation board, which differs from Embodiment 1 in that: the fireproof insulation board includes a passive fireproof layer and a gypsum fireproof board (a total of 2 layers). The passive fireproof layer includes aerogel and fiberglass mat. The aerogel is formed by the curing of aerogel stock solution filling the gaps in the fiberglass mat and wrapping the outside of the fiberglass mat. The aerogel stock solution contains, by weight, 3000 parts of silica sol, 100 parts of lithium silicate, 15 parts of zinc phosphate, 12 parts of quicklime, 10 parts of titanium dioxide, 10 parts of calcium stearate, 45 parts of trimethylchlorosilane (hydrophobic modifier), 5 parts of hydrochloric acid (pH adjuster, adjusting the pH of the aerogel stock solution to 6), and 4000 parts of water.

[0094] The preparation method of the fireproof insulation board is described in Example 1, wherein the glass fiber felt is impregnated in the aerogel stock solution for 30 minutes. The curing conditions are as follows: the unshaped fireproof insulation board is subjected to a pressure of 5 MPa and cured in a curing chamber at 50°C for 30 minutes, then transferred to a microwave band with a frequency of 1000-2500 MHz at 50°C for 20 minutes of aging. Testing shows that the integrated active and passive fireproof insulation board of this embodiment, with a thickness of 24 mm, has a fire resistance limit of over 70 minutes, and its volumetric water absorption rate in humid air is less than 5% after 24 hours.

[0095] Example 3

[0096] This embodiment provides an integrated active and passive fireproof insulation board, differing from Embodiment 1 in that the fireproof insulation board comprises a passive fireproof layer and two layers of gypsum fireproof board, with the passive fireproof layer sandwiched between the two gypsum fireproof board layers. The passive fireproof layer comprises aerogel and mullite fiber felt. The aerogel is formed by the curing of aerogel stock solution filling the gaps in the mullite fiber felt and wrapping the outside of the mullite fiber felt. The composition of the aerogel stock solution is: 2000 parts silica sol, 150 parts sodium silicate, 30 parts aluminum dihydrogen phosphate, 20 parts quicklime, 10 parts titanium dioxide, 10 parts calcium stearate, 20 parts trimethylchlorosilane (hydrophobic modifier), 30 parts dimethyldimethoxysilane (hydrophobic modifier), 10 parts acetic acid, and 3600 parts water. The preparation method of the fireproof insulation board is the same as in Embodiment 1.

[0097] The active and passive integrated fireproof insulation board of this embodiment was subjected to a 1200℃ combustion test (see test conditions). Figure 5 (Photo), recording the fire-exposed temperature 2 and the unexposed temperature 2 of the fireproof insulation board, wherein the temperature curve of the fire-exposed temperature 2 is as follows. Figure 3 As shown, the temperature curve for backfire temperature 2 is as follows: Figure 3 , Figure 4As shown in the figure, when the exposed temperature 2 is 1000-1300℃, the back-fire temperature 2 never exceeds 200℃ within 0-90 minutes of the combustion test, especially maintaining a low temperature of 70-90℃ during the 0-75 minute combustion test period. Therefore, it is evident that the integrated active and passive fireproof insulation board of this embodiment has excellent flame-retardant and heat-insulating effects.

[0098] Example 4

[0099] This embodiment provides an integrated active and passive fireproof and heat-insulating board, such as Figure 2 As shown, the difference from Example 1 is that the fireproof insulation board includes a passive fireproof layer, a gypsum fireproof board, and a magnesium oxide fireproof board. The passive fireproof layer is sandwiched between the gypsum fireproof board and the magnesium oxide fireproof board, forming a sandwich structure. The passive fireproof layer includes aerogel and aluminum silicate fiber felt. The aerogel is formed by the curing of aerogel stock solution filling the gaps in the aluminum silicate fiber felt and wrapping the outside of the aluminum silicate fiber felt. The composition of the aerogel stock solution is based on Example 1 with the addition of 10 parts of phase change microcapsule material. The preparation method of the fireproof insulation board is the same as in Example 1. The phase change microcapsule material is added to the aerogel stock solution in step S3.

[0100] The shell of the phase change microcapsule material is melamine-formaldehyde resin (60% by mass), and the phase change core material is sodium sulfate dodecahydrate (40% by mass). The particle size of the microcapsule material is 100-300 μm. The preparation steps of the phase change microcapsule material can refer to the existing technology or the following method: (1) Dissolve sodium sulfate dodecahydrate in an appropriate amount of warm water at 50-60℃ to form a uniform solution; (2) Add acetone to the container and add 2% of hydrophobic surfactant; (3) Stir at a stirring speed of 15-20 rpm, and slowly add the sodium sulfate aqueous solution to the acetone while stirring to form a stable W / O emulsion; (4) Mix melamine and formaldehyde at a molar ratio of 1:3, and adjust the pH to 8-9 with a pH adjuster to promote the formation of prepolymer. (5) Stir at 15-20 rpm, and gradually add the melamine-formaldehyde prepolymer solution to the aforementioned W / O emulsion while stirring; heat to 85℃ to promote the cross-linking reaction, react for 3 hours, filter, and dry the precipitate to obtain the product.

[0101] The active and passive integrated fireproof insulation board of this embodiment was subjected to a 1200℃ combustion test (see test conditions). Figure 5 (Photo), the temperature curve of the fire temperature is as shown in Figure 1. Figure 3 As shown in Figure 3 (tested simultaneously with the insulation board of Example 1), the temperature curve of the backfire temperature is as follows: Figure 3 , Figure 4As shown in the figure, when the fire temperature is 1000-1300℃, the backfire temperature 3 never exceeds 200℃ during the 0-90min combustion test, especially during the 0-75min combustion test, the backfire temperature 3 remains at a low temperature of 70-90℃. Furthermore, the backfire temperature 3 is consistently lower than backfire temperatures 1 and 2 at all times during the fire exposure period, indicating that the integrated active and passive fireproof insulation board of this embodiment has superior heat insulation capabilities.

[0102] Example 5

[0103] This embodiment provides an integrated active and passive fireproof insulation board, which differs from Embodiment 1 in that the fireproof insulation board includes two passive fireproof layers and three layers of cement fiberboard. The temperature curves of the fire-exposed and unexposed surfaces of the fireproof insulation board show that this embodiment can withstand an unexposed temperature of 1200℃ for more than 110 minutes, and its heat insulation capability further increases with the number of layers, ensuring a stable unexposed surface temperature for a long time, thus possessing excellent and stable fire resistance.

[0104] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A passive integrated fireproof insulation board, characterized in that, Comprising: n passive fireproof layers and n or n+1 active fireproof layers, n is a natural number; The passive fireproof layer and the active fireproof layer are stacked in an alternating or sandwich manner, and are combined into one through pressure gel setting and curing; The active fireproof layer is at least one of inorganic fireproof board materials with heat-decomposing active energy consumption, such as gypsum fireproof board, glass-magnesium fireproof board, cement fiber board and silicate fiber board; the passive fireproof layer comprises inorganic fiber felt as a porous skeleton material and aerogel filled in the pores of the skeleton material and coated outside the skeleton material; the aerogel is obtained by solidification and drying of adhesive aerogel stock solution, and the adhesive aerogel stock solution comprises, by mass fraction, 1000-4000 parts of silica sol, 50-150 parts of soluble silicate, 10-50 parts of phosphate binder, 5-20 parts of quicklime, 5-50 parts of titanium white, 10-50 parts of calcium stearate, 5-50 parts of hydrophobic modifier, 5-50 parts of acid-base regulator and 1000-4000 parts of solvent.

2. The integrative passive fireproof and thermal insulation board according to claim 1, characterized in that, The inorganic fiber felt is one or a mixture of two or more of mullite fiber felt, aluminum silicate fiber felt, glass fiber felt and alumina fiber felt.

3. The integrative passive fireproof and thermal insulation board according to claim 1, characterized in that, In the passive fireproof layer, the mass fraction of the inorganic fiber felt is 70-95%, and the rest is aerogel.

4. The integrative passive fireproof and thermal insulation board according to claim 1, characterized in that, The phosphate binder is at least one of aluminum dihydrogen phosphate, magnesium phosphate and zinc phosphate; and the soluble silicate is at least one of lithium silicate, sodium silicate and potassium silicate.

5. The integrative passive fireproof and thermal insulation board according to claim 1, characterized in that, The adhesive aerogel stock solution further comprises 10-30 parts of phase change microcapsule material by mass fraction, the shell layer of the phase change microcapsule material is silicon dioxide, melamine-formaldehyde resin, polyurea-polyurethane or polyamide, and the phase change core material of the phase change microcapsule material is at least one of paraffin, alkane, fatty acid and its ester, sodium sulfate dodecahydrate, calcium chloride hexahydrate, polyethylene glycol and neopentyl glycol.

6. A method for preparing a passive integrated fireproof insulation board, characterized in that, Comprising: S1: preparing each raw material of the active and passive integrated fireproof insulation board according to any one of claims 1-5, dividing the solvent into two parts, adding soluble silicate, quicklime and titanium white to one part of the solvent and stirring to obtain a mixed solution 1; adding silica sol and phosphate binder to the other part of the solvent and stirring to obtain a mixed solution 2; S2: mixing and stirring the mixed solution 1 and the mixed solution 2, and adding an acid-base regulator to adjust the pH to 6-7 during stirring to obtain a mixed solution 3; S3: adding calcium stearate and a hydrophobic modifier to the mixed solution 3 and stirring to obtain an adhesive aerogel stock solution; S4: dipping the inorganic fiber felt in the adhesive aerogel stock solution until it is fully saturated to obtain inorganic fiber felt impregnated with the aerogel stock solution; S5: stacking the inorganic fiber felt impregnated with the aerogel stock solution with the active fireproof layer to obtain an unshaped fireproof insulation board; S6: first performing pressure gel setting and curing on the unshaped fireproof insulation board, and then performing microwave drying and aging treatment to obtain an active and passive integrated fireproof insulation board.

7. The method of claim 6, wherein the fireproof thermal insulation board is prepared by mixing the inorganic fiber, the binder, the fire retardant, and the water in a predetermined ratio, and then performing a drying process and a curing process. During the mixing and stirring of the mixed solution 1 and the mixed solution 2, an acid-base regulator is added to adjust the pH to 6.

8. The method of claim 6, wherein the fireproof thermal insulation board is prepared by adding 0.1 to 0.5 parts by weight of the inorganic fiber to 100 parts by weight of the cement, and mixing the cement with the inorganic fiber. In step S4, the inorganic fiber mat is dried to remove water in the inorganic fiber mat before being impregnated, so that the inorganic fiber mat can fully absorb the prepared adhesive aerogel stock solution.

9. The method of claim 6, wherein the fireproof thermal insulation board is prepared by adding 0.1 to 0.5 parts by weight of the inorganic fiber to 100 parts by weight of the cement, and mixing the cement with the inorganic fiber. In step S6, the conditions for the pressure gel shaping and curing are keeping at a pressure of 2-5 MPa and a temperature of 30-50 ℃ for 15 min-1 h; the conditions for the microwave drying and aging are drying and aging at a frequency of 1000-2500 MHz and a temperature of 50-100 ℃ for 1-30 min.

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